Note: Descriptions are shown in the official language in which they were submitted.
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RETRACTABLE WALL SYSTEM
AND ADAPTOR COMPONENTS
CROSS-REFERENCE TO RELATED PATENT APLICATIONS
This current application claims priority to United States non-provisional
patent
application entitled "Retractable Wall System" with serial no. 13/844,611
filed March 15,
2013, which is incorporated by reference herein in its entirety.
Also, this current application claims priority to United States provisional
patent
application entitled "Retractable Wall System and Adaptor Components" with
serial no.
61/864,563 filed August 10, 2013, which is incorporated by reference herein in
its entirety.
FIELD OF THE INVENTION
The present invention generally relates to components for a retractable wall
or
awning system. More particularly, this invention relates to a track, two
flanges, an insert, an
entry guide and an end piece for use in a retractable wall system which may be
used to
divide a room or space, create an acoustic barrier, create a freestanding
structure, or
provide an awning.
BACKGROUND OF THE INVENTION
Roller shades may be useful for blocking light and enhancing privacy for
windows.
Retractable walls may provide the ability to divide a room or provide shade
for exterior
porches. Still, a need exits for improved retractable wall systems that may
span longer
distances and utilize heavier fabrics.
SUMMARY OF THE INVENTION
Hence, the present invention is directed to a track for a retractable wall
system which
includes an elongated member having a first cross-sectional profile. The first
cross-sectional
profile may include a front wall, a rear wall spaced from the front wall, and
a bottom wall
connecting the front wall and the back wall. The first cross-sectional profile
may include a
first top wall adjacent the front wall, a second top wall adjacent the rear
wall, and an open
channel disposed between the first top wall and the second top wall. The open
channel may
include a first side wall connected to the first top wall, a second side wall
connected to the
second top wall, a first ledge extending from the first side wall into the
open channel, and a
second ledge extending from the second side wall into the open channel. The
first and
second ledges may define a slot between the first side wall and the second
side wall. The
first cross-sectional profile further may include a conduit disposed between
the front wall and
the rear wall which is connected to the open channel via the slot.
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In another aspect of the invention, the first cross-sectional profile further
may include
a lateral wall that extends from the front wall to the back wall. The conduit
may be formed by
the first ledge, the second ledge, the first side wall, the second side wall,
and the lateral wall.
The lateral wall may be connected to the first side wall and the second side
wall.
In another aspect of the invention, the first cross-sectional profile may
include an
interior wall that extends from the front wall to the back wall. The front
wall, lateral wall, rear
wall and interior wall may define a first interior channel. The front wall,
interior wall, rear wall
and bottom wall may define a second interior channel. The front wall, the
first top wall, the
first side wall and the lateral wall may define a third interior channel. And,
the rear wall, the
second top wall, the second side wall and the lateral wall may define a fourth
interior
channel.
Another aspect of the invention relates to a retractable wall system which may
include a tube having a longitudinal axis, a first track disposed
perpendicular to the
longitudinal axis, a second track spaced from the first track, and a third
track. The third track
may include a first traveling guide disposed in the open channel of the first
track and a
second traveling guide disposed in the open channel of the second track. The
retractable
wall system further may include a flexible membrane barrier sheet connected to
the tube.
The sheet may include first, second and third zippered sides. The first
zippered side may be
disposed in the conduit of the first track and secured to the first traveling
guide. The second
zippered side may be disposed in the conduit of the second track and secured
to the second
traveling guide. The third zippered side may be disposed in the conduit of the
third track.
In another aspect of the invention, the tube may be a thin wall hollow member.
The
tube may have a cross-sectional profile that comprises a substantially
circular outer wall.
The cross-sectional profile further may include a plurality of interior
structural members. The
plurality of interior structural members may each define a chord within the
tube.
In another aspect of the invention, each interior structural member may
connect to an
adjacent structural member to form an external node which is located about the
circumference of the tube. Each interior structural member further may connect
to a second
adjacent structural member to form another external node that is located about
the
circumference of the tube. The intersection of two structural members at an
external node
may form a right angle.
In another aspect of the invention, each interior structural member may
intersect
another interior structural member to form an internal node. The intersection
of two interior
structural members at an internal node may form an obtuse angle, which may
measure
approximately 135 degrees.
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BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein and constitute part
of
this specification, illustrate an embodiment of the invention, and together
with the general
description given above and the detailed description given below, serve to
explain the
features of the invention.
FIG. 1 is a perspective view of a covered patio enclosed on two sides by an
embodiment of the retractable wall system of the present invention;
FIG. 2 is an exploded view of an exemplary embodiment of the retractable wall
system of the present invention;
FIG. 3 is a partial sectional view of the first retractable wall system along
line 3-3 of
FIG. 1;
FIG. 4 is a sectional view of the tube of FIG. 3;
FIG. 5 is a sectional view of another embodiment of the tube of FIG. 3;
FIG. 6 is a perspective view of an exploded view of an idler and tube of FIG.
3;
FIG. 7 is a perspective view of the idler and tube of FIG. 6 being assembled;
FIG. 8 is a partial sectional view of the tube, horizontal track, and flexible
barrier of
FIG 1;
FIG. 8a is a partial sectional view of FIG. 8;
FIG. 9 is a partial cross-sectional view of the left side track and horizontal
track of
FIG. 1, taken perpendicular to the longitudinal axis of the left side track;
FIG. 10 is a cross-sectional view of the horizontal track of FIG. 1, taken
perpendicular
to its longitudinal axis;
FIG. 11 is a cross-sectional view of another embodiment of the horizontal
track of
FIG. 1, taken perpendicular to its longitudinal axis;
FIG. 12 is a partial sectional view of the head rail of FIG. 1, taken
perpendicular to
the vertical tracks and from below the tube and motor assembly;
FIG. 13 is a partial sectional view of the head rail, tube and motor assembly
of FIG.
1, taken parallel to the vertical tracks;
FIG. 14 is an exploded view of the right side end-cap assembly of the
retractable wall
system of FIG. 1;
FIG. 15 is a cross-sectional view of the right side track along with a partial
cross-
sectional view of the horizontal track of FIG. 1;
FIG. 16 is a perspective view of a pair of adjacent tracks and end caps from
abutting
retractable wall systems of FIG. 1;
FIG. 17 is a detailed view of a pair of tracks aligned to form a corner
assembly;
FIG. 17a is a view of the tracks of FIG. 17 fastened together to form a corner
assembly;
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FIG. 18 is a perspective view of a free standing retracting wall system
structure;
FIG. 19 is a plan view of the free standing structure of FIG. 18;
FIG. 20 is a perspective view of an exemplary retractable awning system;
FIG. 21 is a sectional view of the left track of the retractable awning system
of FIG.
20;
FIG. 22 is a side view of the retractable awning system of FIG. 20;
FIG. 23 is a sectional view of the front partition of the retractable awning
system of
FIG. 20;
FIG. 24 is a cross-sectional view of another embodiment of the horizontal
track of
FIG. 1 taken perpendicular to its longitudinal axis and shown in a locked
configuration;
FIG. 25 is a cross-sectional view of the horizontal track of FIG. 24 shown in
a
released configuration;
FIG. 26 is a perspective view of an embodiment of an adaptor flange of the
present
invention;
FIG. 27 is a side view of the adaptor flange of FIG. 26;
FIG. 28 is a perspective view of the tube mating portion of the adaptor flange
of FIG.
26;
FIG. 29 is a perspective view of the insert mating portion of the adaptor
flange of FIG.
26;
FIG. 30 is a perspective view of another embodiment of an adaptor flange of
the
present invention;
FIG. 30b is a perspective view of the tube mating portion of the adaptor
flange of
FIG. 30;
FIG. 31 is a front perspective view of an exemplary embodiment of an adaptor
insert
of the present invention;
FIG. 32 is a rear perspective view of the adaptor insert of FIG. 31;
FIG. 33 is a perspective view of the adaptor flange of FIG. 26 connected to
the tube
of FIG. 5;
FIG. 34 is a perspective view of exemplary adaptor flange and insert assembly
combinations;
FIG. 34B is another perspective view of the exemplary adaptor flange and
insert
assembly combinations of FIG. 34;
FIG. 35 is a front perspective view of an exemplary embodiment of an end piece
of
the present invention;
FIG. 36 is a rear perspective view of the end piece of FIG. 35;
FIG. 37 is a bottom perspective view of an exemplary embodiment of an entry
guide
of the present invention;
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FIG. 38 is a top perspective view of the entry guide piece of FIG. 37;
FIG. 39 is a bottom perspective view of another embodiment of an entry guide
of the
present invention;
FIG. 40 is a top perspective view of the entry guide of FIG. 39;
FIG. 41 is another bottom perspective view of the entry guide of FIG. 39;
FIG. 42 is a front perspective view of another embodiment of an end piece of
the
present invention;
FIG. 42B is a rear perspective view of the end piece of FIG. 42;
FIG. 43 is another rear perspective view of the end piece of FIG. 42;
FIG. 44 is another rear perspective view of the end piece of FIG. 42;
FIG. 45 is another rear perspective view of the end piece of FIG. 42;
FIG. 46 is a cross-sectional view of the adaptor flange of FIG. 26 along line
46-46 of
FIG. 34;
FIG. 47 is a cross-sectional view of the adaptor flange of FIG. 26 along line
47-47 of
FIG. 34;
FIG. 48 is a cross-sectional view of the adaptor flange of FIG. 30 along line
48-48 of
FIG. 34;
FIG. 49 is a cross-sectional view of the adaptor flange of FIG. 30 along line
49-49 of
FIG. 34.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of a patio enclosure 10 formed by three
retractable wall
systems 12, 14, 16. The first retractable wall system 12 may be disposed
perpendicular to
the house and may extend from the side of the house to a first corner of the
patio. The
second retractable wall system 14 may be disposed perpendicular to the first
retractable wall
system 12 and may be parallel to the sliding door of the house. The third
retractable wall
system 16 may be next to the second retractable wall system 14. The first
retractable wall
system 12 may be disposed in an opening under the roof structure of the house.
The first
retractable wall system 12 may include a head rail 18, a left side track 20,
right side track 22,
and a horizontal track 24 disposed between the left side track 20 and the
right side track 22.
In a preferred embodiment, the left side track 20, the right side track 22 and
the horizontal
track 24 have the same cross-sectional profile.
In FIG. 1, the first retractable wall system 12 is in a raised configuration.
In the raised
configuration the horizontal track 24 abuts the head rail 18. Referring to
FIG. 3, the head rail
18 may contain a roll of flexible barrier material 26a, as well as a mechanism
(not shown) 28
for raising and lowering the flexible barrier membrane 26. As shown in FIG. 2,
the
mechanism 28 may include an electrical motor 42, which may be controlled by a
wireless
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remote or switch. Alternatively, the mechanism may include a hand crank or a
chain drive
with a looped strap for manually raising and lowering the flexible barrier
membrane.
Referring to FIG. 1, the left side track 20 of the first retractable wall
system 12 may
be secured to the building. By contrast, the right side track 22 of the first
retractable wall
system 12 may be connected to the left side track 32 of the second retractable
wall system
14 at a 90 degree angle to form a corner assembly. The second retractable wall
system 12 is
shown in a partially lowered configuration. A flexible barrier material 34 may
be disposed
between the left side track 32, right side track 36 and horizontal track 38 of
the second
retractable wall system 14. The flexible barrier material 34 may extend from
inside each of
these three tracks 32, 36, 38 to create a wall.
As shown in FIG. 3, the flexible barrier material 26 may be disposed on a tube
40 in
the head rail. The flexible barrier material 26 may be rolled onto the tube 40
and unwound
from the tube as the horizontal track 24 is lowered. Referring to FIG. 1, the
third retractable
wall system 16 may be disposed parallel to the second retractable wall system
14. The right
side track of the second retractable wall system 14 and the left side track of
the third
retractable wall system 16 may be secured together or connected to a secondary
structural
member (e.g., a post or stud). The third retractable wall system 16 is shown
in the lowered
configuration.
FIG. 2 shows an exploded view of the first retractable wall system 12. The
retractable
wall system 12 may include a left side track 20, a right side track 22, and a
horizontal track
(or weight bar) 24 extending between the left side track and the right side
track. Additionally,
the retractable wall system 12 may include a left side end-cap 46 which is
secured into the
left side track 20 and a left side feeder-clip 48 that is positioned in the
left side end-cap 46.
Similarly, the retractable wall system 12 includes a right side end-cap which
may be secured
into the right side track 22, as well as a right side feeder-clip 52 that may
be disposed in the
right side end-cap 50. When the left side end-cap 46 is fully seated in the
left side track 20
the left side feeder-clip 48 interlocks with features of the left side track
20 cross sectional
profile to further secure the left end-cap to the left side track. Similarly,
when the right side
end-cap 50 is fully seated in the right side track 22, the right side feeder-
clip 52 interlocks
with features of the right side track 22 cross-sectional profile to further
secure the right end-
cap to the right side track. Each end-cap 46, 50 further may include a
cylindrical stub 54 in
the end-cap wall. The cylindrical stub 54 may receive the tube assembly and
serve as axis of
rotation for the tube 40.
The roller tube assembly may include an idler 56, a tube 40 having a central
axis,
and a mechanism 28 for rotating the tube 40 about the central axis of the
tube. In a preferred
embodiment, the mechanism 28 may include a motor 42 that is partially
installed with the
tube 40. The motor 42 may include a built in radio control receiver that
provides a user the
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capability to operate the motor with a remote control. For example, the motor
may be a
Somfy RTS motor.
In FIG. 2, the mechanism 28 for rotating the tube includes a motor 42 with a
remote
control. The motor, which may be slidably received within the tube 40, may
include a drive
58 and a crown 60. The drive 58 and crown 60 may be external features of the
motor which
interlock with an interior surface 62 of the tube so as to provide a mechanism
for transferring
rotational movement from the motor or the tube. The motor 42 further may
include a drive
wheel 64 at one end. The drive wheel 64 may be configured and dimensioned to
be fixedly
received within a motor bracket 66. The motor bracket 66 may be secured to one
end-cap
50. The tube assembly 28 further may include a sheet of flexible material 26.
The sheet of
flexible material 26 may include a zipper border 68 on at least three sides.
The sheet of
flexible material 26 may be cut to be received in a pair of traveling guide
pieces 70, 72 that
are adapted to be received in the horizontal track 24.
FIG. 3 shows a cross-section of the retractable wall system 12 taken
perpendicular to
the central axis 74 of the tube 40. The tube 40 may be mounted on the
cylindrical stub 54 of
the left end-cap 46. The tube 40 may be secured to the idler 54 with a
fastener. Inside the
tube 40 are interior wall segments 78, which form a mating structure for the
motor drive and
crown. The interior wall segments 78 may be arranged to provide structural
rigidity to the
tube. In particular, the interior wall segments may span the internal space of
the tube 40 so
as to provide a three dimensional truss or space frame. Additionally, the tube
may include a
fabric pocket receiving channel 80 and a fabric zipper receiving channel 82,
which may be
used to connect the flexible barrier material 26 to the tube 40. Wrapped
around the tube 40
is a sheet of flexible barrier material 26a, which may include a heat bonded
zipper edge 68
on the left side and the bottom side of the sheet.
The end-cap 46 may be situated within the left side track 20. The left side of
the
flexible barrier material sheet 26 may be fed through the left side feeder-
clip 48 into a rigid
receiving channel 84a in the left side track 20. The bottom side of the
flexible barrier material
26 sheet may be received within the horizontal track 24. The cross-sectional
profile of the left
side track 20 and horizontal track 24 may be the same. Accordingly, the
flexible barrier
material 26 may be secured to the horizontal track 24 through a rigid
receiving channel 86 in
the horizontal track 24. A slot 88 may connect the rigid receiving channel 86
to an internal
anchoring cavity 90 that is configured and dimensioned to receive the bonded
zipper edge
68 of the sheet. The rigid receiving channel 86 may be disposed between a pair
of arcuate
walls 92. The internal anchoring cavity 90 may be disposed adjacent to the
rigid receiving
channel 86.
The horizontal track 24 further may include a primary accessory receiving
channel
94, a secondary accessory receiving channel 96, and a tertiary accessory
receiving channel
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98. Weights, for example, steel bars 100 may be placed with the primary
accessory
receiving channel 94 or the secondary accessory receiving channel 96 of the
horizontal track
24 to facilitate lowering of the flexible material barrier 26. In another
example, sound
dampening material may be inserted in these spaces to increase the sound
insulating
properties of the retractable wall system. An elastomeric end cap, flexible
seal, or brush may
be inserted in the tertiary accessory receiving channel 98 to provide an
improved connection
with the ground surface for purposes such as, without limitation, increasing
wall stability, slip
resistance, draft prevention, or sound dampening.
FIG. 4 shows a cross section of a preferred embodiment of the tube 40.
Generally,
the tube 40 may be a thin-wall hollow member. The outer surface 102 of the
tube may be
substantially circular, and the interior space of the tube may include a
series of interior wall
segments (or structural members) 78, which may reinforce the tube against
bending
moments that may be generated from the weight of flexible barrier material on
the tube when
the tube is positioned between the end caps. Each structural member 78 may
form a cord
within the tube 40. Each structural member 78 may connect to an adjacent
structural
member 78 to form an external node 104, which is located about the
circumference of the
tube. Additionally, each structural member 78 may intersect two other
structural members 78
to form a pair of internal nodes 106. The intersection of a pair of structural
members 78 at an
external node 104 forms a right angle. The intersection of a pair of
structural members 78 at
an internal node forms an obtuse angle of approximately 135 degrees. The space
between
an internal node 106 and outer wall 108 of the tube may be used to house the
pocket
receiving channel 80 and the zipper receiving channel 82. Additionally, a
fastener alignment
groove 110 may be disposed above one or more internal nodes on the outer
surface 102 of
the tube. The interior surface 62 of the tube may form an eight sided shape
for receiving a
motor (with a mating drive and crown) or an octagonal tube for non-motorized
applications
(e.g., 40 mm, 60 mm, or 80 mm tubes).
FIG. 5 shows the cross-section of another embodiment of the tube 40'. In this
embodiment, the outer surface 112 of the tube 40' is substantially circular
and the interior
space includes a series of structural members 114 that reinforce the tube 40'
from bending
moments as in the previous embodiment. In contrast to the tube of FIG. 4,
however, each
structural member 114 connects to the outer wall 116 of the tube at one
location (or external
node) 118. Additionally, the opposite end of each structural member 114 may
connect to an
adjacent structural member 114 to form an internal node 120. The interior
surface 122 of the
tube 40' may form an eight sided shape for receiving a motor (with a mating
drive and
crown) or an octagonal tube for non-motorized applications (e.g., 40 mm, 60
mm, or 80 mm
tubes). In this embodiment, the tube 40' also may include a pocket receiving
channel 124, a
zipper receiving channel 126, and two fastener alignment grooves 128.
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Referring to FIGS. 4 and 5, the tube 40, 40' may have an outer diameter of
approximately 1.0 inches to approximately 6.0 inches, but other dimensions may
be used
where appropriate for the application. In an exemplary embodiment, the tube
40, 40' may
have an outer diameter of approximately 3.5 inches and an interior surface 62,
122 which is
configured and dimensioned to receive a 60 mm octagonal tube. Additionally,
the tubes 40,
40' may range from approximately one foot long to approximately 30 feet in
length. The tube
40, 40' may be formed from aluminum or an aluminum alloy (e.g., 6061 aluminum
alloy
(International Alloy Designation System)), however, other suitable metals,
alloys or materials
may be used to form the tube provided the material has sufficient strength.
For example, the
tube 40, 40' may be formed from a carbon graphite reinforced polymer material.
Preferably,
the tube 40, 40' may be formed by materials having a high strength to weight
ratio and the
ability to be manufactured using extrusion technologies.
Referring to FIG. 4, the flexible barrier material 26 may be secured to the
tube 40 by
a pocket of flexible barrier material 130 and rod 132 inserted within the
pocket receiving
channel 80. In another alternative, the flexible barrier material 26 may be
attached to a
zipper 68 that is inserted into the zipper receiving channel 82. Generally,
the flexible barrier
material 26 may range from approximately 1/32 of an inch in thickness to
approximately 1/2
inch in thickness. The flexible barrier material 26 may be formed, without
limitation, from
natural fibers, leather, PVC, polyester, or acrylic materials. Preferably, the
flexible barrier
material 26 may range from approximately 7 ounces to 60 ounces in weight. In
one example,
the flexible barrier material 26 may be constructed from a 20 ounce vinyl
fabric. In another
example, the flexible barrier material 26 may be constructed from a vinyl
fabric that is
capable of receiving a print design. In another example, the flexible barrier
material 26 may
be constructed from a screen, a transparent material or a natural fabric.
The flexible barrier material 26 may be a single layer of material or a
multilayer
material formed from two or more layers of material. For example, the flexible
barrier
material 26 may be formed from three layers: a middle layer having enhanced
sound
dampening properties (e.g., mass loaded vinyl, Acoustiblok,O) and two outer
fabric layers
(e.g., cotton, polyester, rayon, vinyl, wall paper, or wall covering material)
to create an
acoustic barrier. In another example, the flexible barrier material 26 may be
formed from
clear plastic sound blocking material. Preferably, a flexible barrier material
with enhanced
sound dampening properties may have a STC (Sound Transmission Class) rating of
26 or
greater.
FIG. 6 shows an exploded view of the idler 56 and the tube 40 of FIG. 4. One
end
134 of the idler 56 may be inserted into the tube 40. The opposite end 136 of
the idler 56
may be mounted on the end-cap cylindrical stub 54 (not shown) to form an axis
of rotation.
The tube 40 may include one or more fastener alignment grooves 110. As shown
in FIG. 7, a
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drill (or fastener) 138 may be placed in a fastener alignment groove 110 to
create a fastener
alignment path 140 for securing the idler 56 to the tube 40. The fastener
alignment groove
110 may be located above an internal node 106 of the tube. Placement of a
fastener
alignment groove 110 above an internal node 106 provides a mechanism for
promoting a
repeatable, quick, and straightforward method of securing the idler 56 and the
tube 40 with a
fastener 138. More particularly, the fastener path 140 connects the fastener
alignment
groove 110 and the internal node 106 of the tube. A fastener that is aligned
in this manner
may be expected to penetrate the tube 40 beneath the fastener alignment groove
110 and
be guided by adjacent internal structural members 78 to a position above the
internal node
106. This fastener path may provide a secure connection because the fastener
may be
driven perpendicular to the outer surface of the tube wall and through the
internal node 106
before advancing into and securing the idler 56.
FIG. 8 shows the left side of the flexible barrier member 26 disposed in the
left side
feeder-clip 48 and left side track 20 of the retractable wall system 12. Also,
the bottom of the
flexible membrane barrier 26 is shown locked into the horizontal track 24. As
shown in FIG.
8A, the left side of the flexible material barrier is fully seated within the
traveling guide pin 72.
The full length square cut double pin construction 142 provides rigid
reinforcement of the
flexible barrier material 26 at a leading edge 144 of the sheet. As the
leading edge of the
sheet 144 may be subject to compressive and sheering forces as the barrier is
lowered, the
traveling guide pin 72 may prevent the flexible barrier material 26 from
wearing, tearing,
bunching or binding in the vertical track 20 when the horizontal track 24 is
lowered or raised.
Moreover, as shown in FIG. 9, the traveling guide pin 72 may be configured and
dimensioned to be slidably received within the rigid receiving channel 84 of
the vertical track
20. As the fasteners, which secure the flexible membrane barrier 26 to the
traveling guide
pin 72 are located with the rigid receiving channel 84, they may be recessed
or flush with the
exterior surfaces of the traveling guide pin 72. The zipper portion 68 of the
flexible
membrane barrier 26, when disposed in the internal anchoring cavity 90, pulls
the traveling
guide pin 72 into the rigid receiving channel 84 of the vertical track 20. In
this manner, the
horizontal track 24 and the sides of the flexible membrane barrier 26 may be
securely
positioned within the left side track 20 and the right side track 22.
The reinforcement of the flexible barrier material 26 and tension across the
vertical
tracks 20, 22 may increase the structural integrity of retractable wall system
12, provide for
more reliable operation of the system, and reduce mechanical fatigue of the
zipper-material
interface. Also, the generally uniform tension across the flexible membrane
barrier 26 may
increase the aesthetic appeal of the retractable wall system 12 by enhancing a
uniform
appearance of the flexible barrier material across the structure. Moreover, in
outdoor
applications, this construction may prevent drafts. In sound barrier
applications, this
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construction may promote the deployment of a continuous sound dampening
barrier and
prevent fugitive sound emissions from passing individual barrier elements to
reduce the
effective sound dampening properties of the retractable wall system. Sound
dampening
material may be placed in the primary accessory receiving channel 232, the
secondary
receiving channel 234, and the arcuate receiving channels 236 as well.
The vertical track 20 of the retractable wall system may be secured to a
structural
member such as a stud or post. A pilot hole may be drilled and then a larger
access hole
placed in the track 20 to allow a fastener 150 to be advanced though the
opposite side the
track and into external structural framing 148 to securely attach the vertical
track 20 to
structural framing of an adjacent wall or post.
Referring to FIGS. 10 and 15, the horizontal track 24, the left side track 20,
and the
right side track 22 may share a single cross-sectional profile 152. In FIG.
10, the track profile
152 is shown in use as a horizontal track 24. In this configuration, the
primary accessory
receiving channel 94 may accommodate a weight bar 100, which may be a 1/2 inch
by 3/4
inch steel bar. The weight bar 100 may be positioned within the primary
accessory receiving
channel 94 by the end-cap stem blocking member 154, the upper rail guide 156,
and the
lower rail guide 158.
In FIG. 11, the cross-sectional profile of the track 152' is substantially the
same as in
FIG. 10, but a front portion 160 of the track 24' is removable and forms a
cover. The
removable portion 160 may be secured to the track 24' with snap fittings 162.
This feature
allows weight bars 100 to be installed in the horizontal track 24' after the
retractable wall
structure 12 has been erected. This may improve constructability of the system
and enhance
the safety of workers because handling the horizontal track with preloaded
weight bars 100
is significantly heavier than handling an empty horizontal track.
FIGS. 10 and 11 show an elastomeric cap 164 disposed in the tertiary accessory
channel 96. Arcuate, upper receiving channels 166, as well as the primary and
secondary
accessory receiving channels 94, 96 may receive sound damping materials to
enhance the
sound dampening effect of the retractable wall system.
FIG. 12 shows the left feeder-clip 48 and its tapered guide hole 168. The
tapered
guide hole 168 receives the zippered edge 68 of the flexible barrier material
26 as it spools
off the tube (not shown). Similarly, FIGS. 12 and 13 show the right feeder-
clip 52 and its
tapered guide hole 170, which receives the zippered edge 68 of the other side
of the flexible
barrier material 26. The right feeder clip 52 may further include a circular
passage 172 for
receiving a power cord 174 from the motor 42.
Referring to FIG. 14, the right end-cap 50 may include a stem 176 having a
rectangular channel 178. The right side feeder-clip (or entry guide) 52 may
include a beveled
top surface 180, a central base portion 182, and four plugs 184, 186, 187,
188. One end of
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the feeder-clip 52 may include an elongated and corrugated plug 184. Next to
the elongated
and corrugated plug 184 and disposed in the middle of the feeder-clip 52 may
be a second
plug 186. The second plug 186 may be wider and shorter than the elongated
corrugated
plug 182. Also, a pair of contra-lateral plugs 188, 190 may be disposed on the
other side of
the second plug 186.
The right feeder-clip 52 may include a circular passage 172 that extends from
the
beveled top surface 180 through the second plug 186. The passage 172 may be
configured
and dimensioned to receive an electrical cable for the motor. Additionally,
the beveled top
surface 180 may include a first tapered rectangular passage 170 which extends
through the
feeder-clip 52. A second rectangular passage 192 may extend from the beveled
top surface
180 through the feeder-clip 52 between the contra-lateral plugs 188, 190. The
first
rectangular passage 170 and the second rectangular passage 192 may be
separated by a
thin wall 194. The thin wall 194 may include a tapered slit 176 which extends
from the top of
the thin wall to the bottom of the thin wall.
As shown in FIG. 15 the right feeder-clip 52 may be inserted into the
rectangular
channel 178 of the end-cap 50. The stem 176 of the end-cap may be seated
within the
primary accessory channel 198 and may be positioned in the primary accessory
channel 198
by the upper guide rail 200, the lower guide rail 202, and the end-cap stem
blocking member
204. The second plug 186 of the feeder-clip 52 may be received in the
secondary accessory
receiving channel 206. The secondary accessory receiving channel 206 may be
used to
accommodate an electrical cable 174 that extends from the motor 42 to an
electrical outlet
outside the track. The pair of contra-lateral plugs 188, 190 may be disposed
in the opposing
arcuate cavities 208 at the front of the track. The traveling guide member 72
may be
disposed in the rectangular receiving channel 210 of the track and the
zippered end 68 of
the flexible membrane barrier 26 may be disposed in the internal anchoring
cavity 212. The
material connecting the zipper 68 and the flexible membrane barrier 26 may be
disposed in
the slot 214 between the rectangular receiving channel 210 and the internal
anchoring cavity
212.
FIG. 16 shows an exemplary corner assembly 216 formed from a first end-cap and
track 218 and a second end-cap and track 220. The first end-cap and track 218
and the
second end-cap and track 220 may be disposed at an approximately 90 degree
angle. The
corner assembly 216 may be used to construct adjacent retractable wall
systems, as shown
in FIG. 1.
FIG. 17 shows an exemplary alignment of two tracks 22, 20 which may be used to
construct a corner assembly 216. In the track alignment, the alignment groove
222 in the
primary accessory receiving channel 198 may be disposed opposite the tertiary
accessory
groove 226 of the adjacent track. FIG. 17a shows how the two tracks 20, 32 may
be securely
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fastened to each other. In a preferred method, a guide hole may be drilled
between the
upper and lower guide rails 200, 202 in the primary accessory receiving
channel 198. The
guide hole may be enlarged to an entry hole in order to provide access to the
interior of the
primary accessory receiving channel. A fastener 228 may be positioned in the
alignment
groove 222 (FIG. 17) and advanced into the tertiary accessory groove 226 (FIG.
17) of the
adjacent track. The enlarged hole may be covered with a plastic cap 230.
Referring to FIG. 18, four corner assemblies 216 may be used to construct a
free
standing structure. The free standing structure may be formed from four (or
more)
retractable wall systems 240a, 240b, 240c, 240d, 240e. Two retractable wall
systems 240c,
240d may be joined together to form one side of the structure. One of the
retractable wall
systems 240c may be used as a door for the structure.
Referring to FIG. 19, a short ledge 242 may extend from the lower portion of
the
head rail into the enclosed space. The short ledges 242 of opposing
retractable wall systems
240b, 240e may be used to support beams 244, which may form a cover for the
structure
238. The beams may be used to form a continuous cover or a lattice cover. For
example,
wood boards (e.g., 1"x2" or 2"x4" boards) may be supported by the head rail
ledges to form
a lattice cover, which may allow the structure to be used as a temporary booth
(or Sukkah)
that is constructed for use during the Jewish festival of Sukkot.
Referring to FIGS. 20, the retractable wall system may be adapted for use as
an
awning 246. A webbing material may 248 be molded to the flexible membrane
barrier 250
that forms the awning cover in order to make the canopy stronger while
maintaining light
weight. The awning 246 may include a side pennant 252. As shown, in FIG. 21,
the side
track of the retractable wall system may be modified such that the side frame
254
incorporates a reinforced flexible membrane barrier connection 256 to provide
a taunt but
retractable ceiling canopy. The side frame 254 may include a roller track 258
for a wheel 260
which is connected to the front crossbar 262. Also, the side frame 254 may
include a gutter
264 for collecting and transporting rain water 266. An exterior groove 268 on
the side frame
may be used to house a sealant for sealing the frame to a structure or an
abutting awning
frame.
As depicted in FIGS. 21-23, a reinforced flexible membrane barrier connection
256
may be used to deploy a side pennant 252 with the ceiling canopy. Referring to
FIG. 23, the
front cross bar 262 may support a bracket 270 that holds a loop of canopy
material 272 to
form a pocket to collect and direct rain water 266 to the gutter 264. The
front partition 274 of
the awning structure 246 may include a channel 276 for receiving water from
the gutter. In
another embodiment, the gutter and wheel track may include the same structure.
The front
partition 274 further may include a solenoid 278 that may be used to lock the
awning in the
deployed configuration. Additionally, a brake (not shown) may be available on
the motor end
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and the non-motor end of the awning spool. The retractable wall system may be
constructed
from materials selected to better withstand changes in temperature, corrosion,
or
degradation from ultraviolet light.
Referring to FIG. 24, the cross-sectional profile of the track 300 is
generally the same
as in FIG. 10, but a first portion 302 of the track 300 may be removable, and
may form a
cover. The removable portion (e.g., Part 1) 302 may be secured to a receiving
(or base)
portion 304 (e.g., Part 2) with one or more snap fitting(s) 306. In an
exemplary embodiment,
the snap fitting 306 may be a mechanical joint system where part-to-part
attachment is
accomplished with locating and locking features that are homogenous with one
or the other
of the components being joined. Joining may require the (flexible) locking
features to move
aside for engagement with the mating part, followed by return of the locking
feature toward
its original position to accomplish the interference required to latch the
components together.
Locator features may be inflexible, providing strength and stability in the
attachment. Each
snap fitting (or snap fit locking pair) 306 may be formed from a hook 308 and
an undercut
310. In FIGS. 24 and 25, the undercut 310 may be a cantilevered lug; and the
hook 308 may
be a lip or projection that snaps into the undercut. Assembly of the snap
fitting 306 may
require temporary deformation of one or both pieces, but the parts may return
to an
unstressed state in the final assembled position. Additionally, the retaining
force of a
cantilevered lug may be a function of the bending stiffness of the
cantilevered lug. Thus, the
lugs may be loaded partially to achieve a tight assembly. Although the
retention of each
snap fit locking pair 306 may be releasable, the retention may be permanent in
certain
applications.
As shown in FIG. 24 and FIG. 25, a retention wall 312 and a guide wall 314 may
be
configured and dimensioned to retain an accessory in the primary receiving
channel 316. For
example, the retention wall 312 and guide wall 314 may form parallel sides of
a channel 318
that may hold the accessory, for example, an entry guide piece 320 within the
primary
receiving channel 318 of the track when the cover 302 is removed from the
receiving portion
304. In FIG. 24, the track is shown in an assembled (or locked) configuration
322. During
installation the recessed, square profile 324 of the upper contour of the
track 326 may allow
the track to integrate smoothly with drywall and other construction materials
without the
appearance of cracks or spaces between the finished drywall and track.
Referring to FIG. 25, the track 300 may have a released configuration 328 in
which
the cover 302 is separated from the other part (Part 2) 304. Thus, the cover
302 may be
attached to receiving portion 304, after the receiving portion 304 has been
connected to
other structural members of the retractable wall system. For example, the
entry guide 320
may include a high side fitting 330, a low side fitting 332, a block 334, and
a stem 336, which
are configured to attach to the receiving portion 304 only. Likewise, the
cover 302 may be
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removed from the receiving portion 304 after the retractable wall system has
been installed.
This severability feature allows weight bars to be installed in the primary
receiving channel
316 of a horizontal track of a previously erected retractable wall system. It
also allows for
cabling (e.g., structural, control, or electric cable) to be run through the
secondary receiving
channel 338 after the retractable wall structure (or awning) has been
assembled. Moreover,
sound proofing material may be placed inside the track after the retractable
wall structure (or
awning) has been assembled. The severability feature may improve the
constructability of
the system, as well as enhance worker safety because handling a track with
preloaded
weight bars is significantly heavier than handling an empty horizontal track.
Referring to FIG. 2, in one embodiment of the retractable wall system 12 one
end of
the tube (40, 40') receives a motor assembly 28. A portion of the motor
assembly may be
secured to the bracket 90. The other end of the tube may receive an idler 56.
The idler may
include a ring of ball bearings that may be disposed on the end cap pin 54. In
another
embodiment, the idler may be spring loaded. In yet another embodiment the
idler may be
replaced with a "Chinese spring," which stores energy as the retractable wall
is lowered and
releases stored energy as the retractable wall is raised. The energy released
by these
devices may assist in retracting the wall. An energy storage device (e.g., a
spring loaded
idler or "Chinese spring") may be used in combination with a manual gearbox on
the one end
of the tube, in place of the electric motor assembly. Alternatively, an energy
storage device
may be used in combination with a chain drive mechanism on one end of the
tube, instead of
the electric motor assembly.
Referring to FIGS. 26-27, an adaptor flange 340 may be used to connect a
retractable wall system (FIG. 2) tube 40 to the end caps 46, 50. The adaptor
flange 340 may
have a flange 342 disposed between two working end portions 344. For example,
one
working end portion 346 of the adaptor flange may be configured and
dimensioned to mate
with the tube. By contrast, the other end 348 of the adaptor flange may be
configured and
dimensioned to mate with a customized insert 350 (FIG. 31 and FIG. 32) which
in turn may
be adapted to connect to a gear box, drive chain, or mounted on an end cap pin
or like
bracket.
Referring to FIG. 28, the tube mating portion 346 may include one or more
faces 352
that interlock with the internal features of the tube. For example, the one or
more faces 352
of the tube mating portion 346 may be configured and dimensioned to form a
press fit plug
with the tube. For instance, interior wall segments or structural members 78
(FIG. 9) of the
tube may receive and retain the press fit plug. The press fit plug may include
four drive faces
354 and four rail faces 356. In one embodiment, a rail face 356 may include a
base 358 and
at a fin 360. Although the embodiment of the tube mating portion shown in FIG.
28 has an
axis of symmetry, any configuration of plug features and fasteners may be used
to connect
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with the tube end, provided the tube mating portion 346 is securely connected
to the tube,
rotation of the flange 342 turns the tube about an axis, and the structure can
readily
withstand the torque necessary to rotate the tube.
Referring to FIG. 29, the insert mating portion 348 may include a tube member
358
that is configured and dimensioned to mate, for example, with an idler, a
spring loaded idler,
an electric motor assembly, or a "Chinese spring." Additionally, the hollow,
tube member 358
may be configured and dimensioned to mate with the reversible insert of FIG.
31. In the
embodiment shown in FIG. 29, the hollow, tube member 358 is circular
cylindrical, however,
a cylinder of any shape may be used provided that the tube member is adapted
to cooperate
with a drive mechanism (or hinge joint) that may be connected to (or cooperate
with) an end
cap. The outer surface of the hollow tube member 358 further may include
structural
elements 360 that reinforce the flange-tube member interface against sheering
forces. The
structural members 360 may include a plurality of reinforcing members. One (or
more) of the
reinforcing members 360 may form a buttress between the tube member 358 and
the flange
342.
The adaptor flange 340 may have a leading end 362, a trailing end 364, and an
internal side wall 366 extending from the leading end to the trailing end. The
internal side
wall may define a passage through the adaptor flange 340. The internal side
wall 366 may
include one or more grooves. A groove 368 may extend from the leading end 362
to an
interior location on the internal side wall 366. Another groove(s) 370 may
have a square cut.
Yet another groove 372 may be spaced from the leading end groove 368 and the
square cut
groove(s) 370 on the side wall. The square cut groove(s) 370 may be configured
and
dimensioned to receive a raised key on the crown of an electrical motor
assembly or similar
accessory. For instance, the one or another square cut groove(s) 370 may be
configured to
receive one or more raised keys on the head of a Chinese spring. Additionally,
the leading
end groove(s) 368, 372 may be configured and dimensioned to receive a radial
projection on
the reversible insert 350 (FIGS. 31-32). A slot or opening on the groove 374
may extend
through the side wall to provide a fastener attachment site for securing a
fastener to the
adaptor flange 340 and the flange accessory (e.g., crown of electrical motor,
Chinese spring,
and reversible insert 350).
FIGS. 30 and 30b show another embodiment of an adaptor flange 376 of the
present
invention. The adaptor flange 376 may be configured and dimensioned to mate
with a
conventional awning tube or a galvanized steel roller tube. In this
embodiment, the tube
mating portion 378 may include three different connectors for securing the
tube mating
portion 378 within a conventional tube. For instance, the connectors may
include a plurality
of blocks 380, primary rails 382 and secondary rails 384, as well as a wing
that forms a
buttress between the flange 342 and the primary rails 380. The distribution of
the connectors
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may be uniform or may form a pattern around the exterior side wall of the tube
mating
portion 378. For example, pairs of like connectors may be disposed about the
circumference
of the tube mating portion at a radial interval of approximately 180 degrees.
In one
configuration, one primary rail 380 may be disposed next to each lateral edge
of the
respective flange cutouts 388. The primary rails 380 may define a passage 390
behind the
flange cutout 380 that allows a loop of awning material to be slipped into a
tube pocket (see
FIG. 33). The primary rails 380 may be reinforced with a wing structure 386
that buttresses
the primary rail with respect to the flange. A pair of blocks 380 may be
disposed on either
side of the primary rails 384 to provide additional structural support for the
inner wall of the
tube. A pair of secondary rails 384 may be disposed between two pairs of
blocks 380. Each
rail may include a fin 392 that projects beyond an imaginary circumference
defined by the
end surface of the rail base and blocks so as to provide for a tighter, more
secure press fit to
the tube.
FIG. 31 shows an exemplary embodiment of an insert 350. The insert 350 may
include a body 394 formed from a cylindrical member. The cylindrical member
may have a
central axis 396 as well as a proximal end 398 and a distal end 340. The
cylindrical member
may be circular cylindrical. The cylindrical member may be tapered such that
the diameter at
one end of the member is larger than at the opposite end. The insert 350 may
include a nose
402 adjacent to the proximal end 398. The nose 402 may include a bearing
receiving port
404. The bearing receiving port 404 may include an annular wall 406 that
defines a circular
cylindrical port which may be configured and dimensioned to receive a ring of
ball bearings.
One or more reinforcing members 408 may connect the circumference of the
annular wall
406 to the body 394 in order to buttress the nose 402 against sheering forces.
The distal end
400 of the body 394 may include internal structures 410 that are adapted to
receive the
driver of a gearbox or a pulley chain drive. The insert may further include
one or more radial
projections 412 on the body. Each radial projection 412 may be configured
and
dimensioned to mate with a respective groove 368, 372 on the internal side
wall 366 of
either adaptor flange described above. Additionally, the one or more radial
projections 412
may be located on the body 394 such that: (1) the nose 402 protrudes from the
adaptor
flange when the distal end 400 is inserted into the adaptor flange; and (2)
the gearbox or
drive chain receiving end 398 are flush with the distal end 400 of the insert
when the nose
402 is inserted in to the adaptor flange. (e.g., FIG. 34). This spacing
differential provides the
necessary space for the gearbox or drive chain assembly in the end cap when
the distal end
of the insert is disposed within the flange. Similarly, the spacing
differential provides the
necessary space for the bearing ring cage to mount on the end cap stub 54 (or
similar
structure).
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FIG. 32 shows the distal end 400 of the insert of FIG. 31. The distal end 400
of the
inset 394 may include a plurality of structural reinforcing members 410 inside
the insert. The
orientation of the structural reinforcing members 410 may be designed to make
the insert
394 more resistant to bending moments and sheering forces. The internal
structural
reinforcing members may provide added rigidity to the insert 394 so as to
prevent bending
and cracking of the insert under the static and dynamic loads attendant to
mounting and
operating the tube-flange-insert assembly. Additionally, the structural
reinforcing members
410 may define a driver receptacle 414 for receiving the driver of a manually
operated gear
box or the driver of a pull chain mechanism.
As shown in FIG. 33, the tube mating portion 352 of the adaptor flange 340 may
be
inserted into the tube 40 until the flange 342 contacts the end 418 of the
tube. The adaptor
flange may be oriented such that the flange cutouts 416 are generally aligned
with the
pocket receptacles 124, 126. Depending on the application, an insert 350,
motor 42, idler or
"Chinese spring" may be placed into the insert receiving end (or insert mating
end) 348 and
interlocked with the appropriate grooves 368, 372 on the internal sidewall
366.
FIG. 34 and FIG. 34b show a rear and front perspective view, respectively, of
two
adaptor flange embodiments 340, 376 with the insert 350 of FIGS. 31-32.
Referring to FIG. 34, one adaptor flange 340 and insert 350 assembly
configuration
542 depicts the insert 350 after being placed within the adaptor flange 340
from the insert
mating portion 348 with the proximal end 398 of the insert 350 facing inward.
In this
configuration 542, the bearing receiving port 404 is not available for use at
the working end
344 of the insert mating portion 348 of the adaptor flange 340. Instead, the
distal end 400 of
the insert 350 is available for use at the working end 344 of the insert
mating portion 348 of
the adaptor flange 340. As shown in FIG. 34B, this configuration of the
adaptor flange 340
and insert 350 assembly 542 provides working access to the driver receptacle
414 on the
distal end of the insert 400. The radial projection(s) 412 of the insert 350
are disposed and
interlocked within the leading end groove(s) 368 of the adaptor flange 340.
The distal end
400 of the insert 350 may be flush with the working end portion 344 of the
adaptor flange
340. In this configuration, the driver of a manual gearbox may be inserted
into the driver
receptacle 414 to rotate the adaptor flange 340 and insert 350 assembly 542.
Referring to
FIG. 46, internal structures 410 of the insert 350 strengthen (or reinforce)
the assembly 542
from sheering forces and bending moments associated with a tube connected to
the tube
mating portion 346 of the adaptor flange 340. In another operable
configuration of the
adaptor flange 340 in which the insert 350 is not used, one or more square cut
grooves 370
may be used to interlock with an electric motor or spring assembly. Referring
to FIG. 47, a
rail face(s) 354 and a drive face(s) 356 of the adaptor flange 340 may bear on
an interior
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surface(s) 62 of the tube so as to provide a mechanism for transferring
rotational movement
from the driver of a manual gearbox or other device.
Referring to FIG. 34, another adaptor flange 340 and insert 350 assembly
configuration 544, depicts the insert 350 after being placed within the
adaptor flange 340
from the insert mating portion 348 with the distal end 400 of the insert 350
facing inward. In
this configuration 544, the bearing receiving port 404 is available for use at
the working end
344 of the insert mating portion 348 of the adaptor flange 340. The proximal
end of the insert
398 may project from the working end 344 of the insert mating portion 348. The
proximal end
of the insert 398 may project from the working end 344 of the insert mating
portion 348 such
that a ring bearing placed in the bearing receiving port 404 may be received
onto a
cylindrical stub 54 of an end-cap wall. As shown in FIG. 34B, this
configuration of the
adaptor flange 340 and insert 350 assembly 544 provides working access to the
bearing
receiving port 404 on the proximal end of the insert 398. The radial
projection(s) 412 of the
insert 350 are disposed and interlocked within the leading end groove(s) 368
of the adaptor
flange 340. In this configuration 544, a bearing ring cage may be placed in
the bearing
receiving port 404, which may be disposed onto a cylindrical stub 54 of an end-
cap wall.
Referring to FIG. 34, another adaptor flange 376 and insert 350 assembly
configuration 546 depicts the insert 350 after being placed within the adaptor
flange 376
from the insert mating portion 348 with the proximal end 398 of the insert 350
facing inward.
In this configuration 546, the bearing receiving port 404 is not available for
use at the
working end 344 of the insert mating portion 348 of the adaptor flange 376.
Instead, the
distal end 400 of the insert 350 is available for use at the working end 344
of the insert
mating portion 348 of the adaptor flange 376. As shown in FIG. 34B, this
configuration of the
adaptor flange 376 and insert 350 assembly 546 provides working access to the
driver
receptacle 414 on the distal end of the insert 400. The radial projection(s)
412 of the insert
350 are disposed and interlocked within the leading end groove(s) 368 of the
adaptor flange
376. The distal end 400 of the insert 350 may be flush with the working end
portion 344 of
the adaptor flange 376. In this configuration, the driver of a manual gearbox
may be inserted
into the driver receptacle 414 to rotate the adaptor flange 376 and insert 350
assembly 546.
Referring to FIG. 48, internal structures 410 of the insert 350 strengthen (or
reinforce) the
assembly 546 from sheering forces and bending moments associated with a
conventional
tube connected to the tube mating portion 346 of the adaptor flange 376. In
another operable
configuration of the adaptor flange 376 in which the insert 350 is not used,
one or more
square cut grooves 370 may be used to interlock with an electric motor or
spring assembly.
Referring to FIG. 49, block(s) 380, primary rails 382, and secondary rail(s)
384 may bear on
an interior surface(s) 62 of the conventional tube 40" so as to provide a
mechanism for
transferring rotational movement from the driver of a manual gearbox or other
device.
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Referring to FIG. 34, another adaptor flange 376 and insert 350 assembly
configuration 548, depicts the insert 350 after being placed within the
adaptor flange 376
from the insert mating portion 348 with the distal end 400 of the insert 350
facing inward. In
this configuration 548, the bearing receiving port 404 is available for use at
the working end
344 of the insert mating portion 348 of the adaptor flange 376. The proximal
end of the insert
398 may project from the working end 344 of the insert mating portion 348. The
proximal end
of the insert 398 may project from the working end 344 of the insert mating
portion 348 such
that a ring bearing placed in the bearing receiving port 404 may be received
onto a
cylindrical stub 54 of an end-cap wall. As shown in FIG. 34B, this
configuration of the
adaptor flange 376 and insert 350 assembly 548 provides working access to the
bearing
receiving port 404 on the proximal end of the insert 398. The radial
projection(s) 412 of the
insert 350 are disposed and interlocked within the leading end groove(s) 368
of the adaptor
flange 376. In this configuration 548, a bearing ring cage may be placed in
the bearing
receiving port 404, which may be disposed onto a cylindrical stub 54 of an end-
cap wall.
FIG. 35 shows another embodiment of an end piece 420 that may be used with a
horizontal track 24 of the retractable awning system 12. The end piece 420 may
include an
upper guide plug 422 which is configured and dimensioned to form a press fit
with the
secondary accessory receiving channel 338 of the track 300. The end piece
further may
include a lower guide plug 424 which is configured and dimensioned to form a
press fit with
the primary accessory receiving channel 316 in the track 300. As described
above, the end
piece may include two planar members 426 and a slot 428 between the planar
members 428
for receiving flexible barrier material 26. The planar members 426 may include
fastener
holes 430 for securing a flexible barrier material in the slot 428 between the
planar members
to form a flexible barrier material guide for a retractable wall system 12.
FIG. 36 shows the end piece 420 from a rear perspective view. Visible from
this view
are fins 430 on the upper guide plug 422 and the lower guide plug 424 for
helping to create a
tight press fit between the plugs and their respective accessory channels.
Additionally,
opposing surfaces 432, 434 on the upper guide plug and the lower guide plug,
respectively,
may define a crevice 436 for receiving the track wall 438 (FIG. 24 and FIG.
25) that
separates the primary accessory receiving channel 316 and the secondary
accessory
receiving channel 338. The end piece may further include a bumper 440. The
bumper 440
may generally correspond to the profile of a portion of the track 300 that is
situated next to
the end piece 420.
FIGS. 42-45 show yet another embodiment of an end piece 442. FIG. 42 and FIG.
42b show an end piece 442 which may be used with the track 300 of FIG. 24 and
FIG. 25.
The end piece 442 may include an upper guide plug 444 which may be configured
and
dimensioned to form a press fit with the secondary accessory receiving channel
338 of the
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track 300. The lower guide plug 446 may be configured and dimensioned to form
a press fit
with the primary accessory receiving channel 316 in the track 300. The end
piece further
may include a plate 448 and two prongs 450 extending from the plate.
Furthermore, the end
piece 442 may include opposing surfaces 452, 454 on the upper guide plug 444
and the
lower guide plug 446, respectively, may define a crevice 456 for receiving the
track wall 438
(FIG. 24 and FIG. 25), which may separate the primary accessory receiving
channel 316 and
the secondary accessory receiving channel 338. The end piece 442 may further
include a
bumper 458. The bumper 458 may generally correspond to the profile of a
portion of the
track 300 that is situated next to the end piece 442. Also, the end piece 442
may include
two planar members 460 and a slot 462 between the planar members 460 for
receiving
flexible barrier material 26. The planar members 460 may include fastener
holes 464 for
securing flexible barrier material in the slot 462 to form a flexible barrier
material guide for
the retractable wall system 12.
Each prong 450 may be disposed on one side of the fabric receiving slot 462.
Referring to FIG. 24 and FIG. 25, the prongs 450 may be configured and
dimensioned to
form a press fit with walls of the internal anchoring cavity 466 on the
receiving portion 304 of
the track 300. This may allow the cover 302 of the track 300 to be snapped
into place after
the end piece 442 has been installed into the receiving portion 304. This may
have particular
utility in allowing the retractable wall system 12 to be erected initially
with receiving portion
304 only. Thereafter weight bars may be loaded into the primary accessory
receiving
channel 318. Then the cover 302 may be connected to the receiving portion 304
to complete
the horizontal bar assembly.
FIGS. 43-45 show the end piece of FIG. 42 from various rear perspective views.
Visible from these views are fins 468 on the upper guide plug 444 and lower
plug 446 for
helping to create a tight press fit between the plugs and their respective
accessory channels.
Fins 468 on the lower guide plug 446 may be positioned to form a press fit
with the walls
which form the tertiary accessory receiving channel 98, 224 (see e.g., FIGS.
10, 11 and 15).
In this embodiment, the fins 468 are positioned to form a press fit with the
receiving portion
304 only. Also, the fins 468 may be hard and sharp enough to score the track
300 to further
provide a secure and tight fit. The bumper 458 may conform to the square cut
of the two
piece track 300 shown in FIG. 24 and FIG. 25.
FIG. 37 shows another embodiment of an entry guide 470. As previously
described in
connection with FIGS. 14 and 15, an entry guide 52, 470 may be inserted into
the top end of
the right side vertical track 22. A mirror image of the entry guide may be
used for the left side
vertical track 20. The entry guide 470 may be configured and dimensioned to
create a press
fit with the track 22 and stem 176 of the associated end cap 50. The entry
guide may include
an upper surface 472 and a lower surface 474, which is configured and
dimensioned to abut
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the track when fully inserted into the track. The entry guide 470 further may
include a stem
476, which projects from the lower surface 474 of the entry guide. The stem
476 may
possess serrations (or teeth) 478 on its lateral sides. The stem 478 may be
configured and
dimensioned to form a press fit with the retention wall 312 and guide wall 314
in the primary
accessory receiving channel 316 (FIG. 24). The entry guide 470 may further
include a block
480 that is disposed adjacent to the stem 478 on the lower surface 474 of the
entry guide.
The block 480 may include a central landing 482 bounded by a pair of tapered
risers 484
and treads 486 on one or more lateral faces of the block. The block 480 may
further include
a side wall 488 which extends from the rear surface of the block to an
interior of the block.
The side wall 488 may extend from the rear surface of the block to the upper
surface 472 of
the entry guide. The side wall 488 may form a through bore 490 that extends
from the rear
surface of the block to the upper surface of the entry guide. The through bore
may have a
central axis and a cross-sectional area perpendicular to the central axis. The
cross-sectional
area may be uniform or may vary through the entry guide. The through bore 490
may be
sized for passage of an electrical motor cable or a steel tensioning cable.
The size of the
through bore 490 may be selected for the particular application. The block may
be
configured and dimensioned to form a press fit with the secondary accessory
receiving
channel 338. The entry guide 470 further may include a high side fitting 492
and a low side
fitting 494 which may be configured and dimensioned to form a press fit with
the upper
channels of the track.
Referring to FIG. 38, one side of the entry guide may be taller than a second
side,
and thus the upper surface 472 of the entry guide may form a diagonal surface
that slopes
from the high side to the low side of the entry guide. The entry guide may
include a feed slot
496 and guide channel 498 disposed between the high side fitting 492 and the
low side
fitting 494. The feed slot 496 and guide channel 498 may taper from a wider
opening 500 at
the upper surface to a more narrow opening 502 at the lower surface of the
entry guide. The
through bore 490 is also visible in FIG 38, along with the cut out 504 for the
end cap stem.
FIGS. 39-41 show yet another embodiment of an entry guide 506 (or feeder clip
52).
As previously described in connection with FIGS. 14 and 15 above, an entry
guide 506 may
be inserted into the top end of the right side vertical track. A mirror image
of the entry guide
506 may be used for the left side vertical track. The entry guide 506 may be
configured and
dimensioned to create a press fit with the track 300 and stem of the
associated end cap. The
entry guide 506 may include an upper surface 508 and a lower surface 510,
which is
configured and dimensioned to abut the track when fully inserted into the
track. The entry
guide 506 may further include a stem 512 which projects from the lower surface
510 of the
entry guide. The stem 512 may possess serrations (or teeth) 514 on its lateral
sides. The
stem 512 may be configured and dimensioned to form a press fit with the
retention wall 312
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and guide wall 314 in the primary accessory receiving channel 316 (FIG. 24).
The entry
guide 506 further may include a block 516 that is disposed adjacent to the
stem 512 on the
lower surface 510 of the entry guide. The block 516 may include a central
landing 518
bounded by a pair of tapered risers 520 and treads 522 on one or more lateral
faces of the
block. The block may be configured and dimensioned to form a press fit with
the secondary
accessory receiving channel 339.
As shown in FIGS. 39-41, the block 516 of this entry guide may include a side
wall
524 as described in connection with the embodiment of FIG. 37 and FIG. 38.
Accordingly, a
side wall may extend from the rear surface of the block to the upper surface
of the entry
guide. The side wall may form a through bore 526 that extends from the rear
surface of the
block to the upper surface of the entry guide. The through bore 526 may have a
central axis
and a cross-sectional area perpendicular to the central axis. The cross-
sectional area may
be uniform or may vary through the entry guide. The through bore may be sized
for passage
of an electrical motor cable or a steel tensioning cable. The size of the
through bore may be
selected for the particular application.
Referring to FIG. 39, the entry guide 506 may include a high side fitting 528
and a
low side fitting 530 which may be configured and dimensioned to form a press
fit with the
walls of the internal anchoring cavity 466 on the receiving portion 304 of the
track 300 (FIGS.
24 and 25). Such a configuration allows the cover 302 of the track 300 to be
snapped into
place after the end piece has been installed into the receiving portion 304.
This may have
particular utility in allowing the retractable wall system to be erected
initially with the
receiving portion 304 only. Thereafter cables may be strung through the bore
in the block
and the secondary accessory channel 339 of the track 300. The cover may be
connected to
the receiving portion 304 after the cable has been strung to complete the
vertical track
assembly.
Referring to FIG. 40, one side of the entry guide 506 may be taller than a
second
side, and thus the upper surface of the entry guide 506 may form a diagonal
surface that
slopes from the high side to the low side of the entry guide. The entry guide
506 may include
a feed slot 532 and guide channel 534 disposed between the high side fitting
528 and low
side fittings. The feed slot 532 and guide channel 534 may taper from a wider
opening 536
at the upper surface to a more narrow opening 538 at the lower surface of the
entry guide.
Also, visible in FIG. 40 is the cutout 540 for the end cap stem.
While it has been illustrated and described what at present are considered to
be
preferred embodiments of the present invention, it will be understood by those
skilled in the
art that various changes and modifications may be made, and equivalents may be
substituted for elements thereof without departing from the true scope of the
invention.
Additionally, features and/or elements from any embodiment may be used singly
or in
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combination with other embodiments. Therefore, it is intended that this
invention not be
limited to the particular embodiments disclosed herein, but that the invention
include all
embodiments falling within the scope and the spirit of the present invention.
24
